Darkly colored cleansing article with distributed polymeric network

ABSTRACT

A darkly colored article especially suitable for cleansing skin having the general form of a fibrous bar is described. The article includes a solid or semi-solid lathering composition that at least partially incorporates a continuous fabricated polymeric network. By including a network that has a CIE Lightness Value of less than about 50, especially an achromatic network, darkly colored cleansing articles can be provided that have minimum staining potential and exhibit good color stability during storage and use.

FIELD OF INVENTION

The invention relates to darkly colored personal cleansing articles having the form of a fibrous bar wherein a solid or semi-solid lathering composition at least partially incorporates a continuous fabricated polymeric network. The cleansing articles have a dark color without staining, and exhibit good color stability during storage and use.

BACKGROUND OF INVENTION

Consumers have been increasingly receptive to new personal washing systems that provide a greater sense of refreshment, lead to a more pleasurable bathing and showering experience, and/or are personalized. Although toilet bars are still widely used because of their convenient form and simplicity, liquid products and more recently sheets have grown in popularity.

Consumers recognize that liquids provide excellent skin care and fragrance attributes. Further the variety of packaging, unique colors, and other visual features, especially available in the specialty trade, provide more individualistic and upscale products. However, liquids do not lather well without the use of an additional implement and without such an implement, liquids are not perceived as economical or as convenient as bars. Sheets in contrast, lather well but are generally single-usage forms and thus are primarily used in facial washing where the perceived benefits more readily justifies their higher cost.

Liquid and sheet personal washing forms have primarily been targeted to female consumers, and these forms are not so widely used by men who often prefer bars for their convenience and refreshment qualities.

Despite the growth of cosmetic products targeted to male consumers, male oriented soap bars have changed little since the introduction of so called refreshment or deodorant bars over 30 years ago many of which have a striated or variegated appearance.

Thus, there is a need for cleansing articles that have the convenience and economy of a bar but with highly differentiated sensory properties that are appealing to men. One of these differentiating properties is a dark color. Although darkly colored or black soap bars have appeared from time to time they have not enjoyed much success because of the limitations of conventional soap bar technology. In particular, darkly colored soap bars tend to discolor (turn pale or gray) in storage or use. Furthermore, the level of colorant required for high color saturation has the potential for staining and often leads to unsightly residue collecting in soap dishes or on other surfaces.

The following patents and publications form a part of the related art:

U.S. Pat. No. 4,613,446 describes plastic mesh pads and sponges impregnated with a soft paste-like cleansing composition including an alkali metal phosphate, a wetting agent, fatty acid soap, a chelating agent and surfactant. The articles are designed to be used as large size scouring pieces for cleaning tires, vinyl tops and trims, bumpers and other surfaces.

U.S. Pat. No. 3,949,137 describes a gel-impregnated sponge composed of two layers: one layer is impregnated with a hardened gel material and one layer is a non-impregnated sponge.

U.S. Pat. No. 5,221,506 describes a bar soap having a sponge core which is revealed after the soap bar is reduced to a sliver, said sponge core providing support and preventing breakage of the sliver thus reducing wastage.

U.S. Pat Application Publication No. 2003/0220212 A1 describes bar soap reinforced with a reinforcement member such as a mesh to prolong the usage of the bar.

U.S. Pat. No. 6,190,079 describes a scrubbing soap bar composed of vegetable oil and glycerin into which is partially imbedded a thin fine-mesh netting that serves as a feature to facilitate grasping and holding the bar.

U.S. Pat. No. 4,969,225 relates to a bathing and cleansing article in the form a scrub brush specifically made to contain or hold a bar of soap.

U.S. Pat. No. 4,190,550 describes a seamless fibrous, soap-filled pad in the form of an envelope that surrounds a solid soap, which is held in integral form by the entanglement of the fibers.

U.S. Pat Application Publication No. 2004/0033915 A1 relates to cleansing bars including a cleansing composition and a plurality of discrete elements (e.g., fibers) having a length to diameter ratio of from about 50 to 1 to about 100,000 to 1.

EP 1 266 599 A1 describes a solid cleanser holder composed of an apertured textured film surrounding a solid cleanser. The film reduces slip, exfoliates and enhances lather.

U.S. Patent Application Publication No. 2005/0113270 A1 to Stockman et al published May 26, 2005 relates to scrubbing soap bar having an embedded scrubbing element.

U.S. Pat. No. 6,6896,435 to James W. Rink issued May 24, 2005, describes a slip-resistant floating soap having two outer convex shaped layers of soap connected by a water impermeable buoyant material extending around the outer soap layers to provide slip resistance.

U.S. Pat. No. 6,893,182 to Chung Min Liao issued May 17, 2005 describes a soap device having an embedded spongy or perforated cleansing device.

The present invention seeks improvements over deficiencies in the known art. Among the one or more problems addressed include the development of a darkly colored personal cleansing article having the overall form of a bar that appeals especially to male consumers and has a lower potential for staining, messy residue, and discoloration during storage and use.

SUMMARY OF THE INVENTION

The inventors have developed darkly colored cleansing articles having the general form of a bar that can be manufactured in a variety of shapes. By including a certain types of darkly colored or dark achromatic polymer networks in a lathering composition, good color stability and lower potential for residue or staining has been achieved.

In particular, the personal cleansing article is a darkly colored fibrous bar that includes:

-   -   i) a continuous fabricated polymer network; and     -   ii) a solid or semi-solid lathering composition at least         partially encompassing the continuous fabricated polymer         network;

wherein the continuous fabricated polymer network has a substantially black color defined by having a CIE Lightness Value, L*, of less than about 50, preferably less than about 30, and most preferably less than about 25;

wherein the solid or semisolid lathering composition is either transparent or has a substantially black color defined by a CIE Lightness Value, L*, of less than of less than about 50, preferably less than about 40, and most preferably less than about 30; and

wherein the weight ratio of the lathering composition to the fabricated polymer network is in the range from about 30 to 1 to about 2000 to 1.

In one embodiment, the continuous fabricated polymer network is a non-woven, 3-dimensional network of bonded fibers.

In another embodiment the fabricated polymer network is distributed throughout at least about 55%, preferably at least about 75% and more preferably at least about 90% of the volume of the lathering composition.

In another embodiment, the lathering composition and the fabricated polymer network are substantially color matched.

In another embodiment, the lathering composition includes an organic benefit agent having an octanol/water partition coefficient of at least about 500, and an amount of water or water plus optional water soluble organic solvent of at least about 40% by weight of lathering composition.

These and other variations of the articles disclosed herein will become clear from the description of the invention which follows.

DETAILED DESCRIPTION OF THE INVENTION

As used herein % or wt % refers to percent by weight of an ingredient as compared to the total weight of the composition or component that is being discussed.

Except in the operating and comparative examples, or where otherwise explicitly indicated, all numbers in this description indicating amounts of material or conditions of reaction, physical properties of materials and/or use are to be understood as modified by the word “about.” All amounts are by weight of the final composition, unless otherwise specified.

For the avoidance of doubt the word “comprising” is intended to mean “including” but not necessarily “consisting of” or “composed of.” In other words, the listed steps or options need not be exhaustive.

The subject invention provides a darkly colored article for personal cleansing having the general aspect or form of a fibrous bar that includes a solid or semi-solid lathering composition within which is at least partially distributed a substantially black fabricated polymeric network.

The fabricated polymer network, the lathering composition and methods to prepare and evaluate the inventive article are described in detail below.

Fabricated Polymer Network

The inventive article includes a fabricated polymer network (hereinafter alternatively designated “FPN”) at least partially distributed in a solid or semi-solid lathering composition (hereinafter alternatively designated “lathering composition”) as described below. By the term partially distributed is meant that the fabricated polymer network should occupy at least 55%, preferably at least 75% and most preferably at least about 90% of the volume of the lathering composition.

It should be understood that the fabricated polymer network is a porous network, preferably a highly porous network, comprised of a minor volume fraction of solid polymer and a major volume fraction of “void space”. This void space is occupied by the medium in which the FPN is immersed. Consequently, although the FPN occupies most of the geometric volume of the lathering composition as well as the fibrous bar, it generally makes up only a small fraction on a weight basis: about 0.05% to about 3% by weight of the fibrous bar.

By a “fabricated polymeric network”, is meant that the network is synthetic or man-made, and that this network is predominantly composed of a polymeric material. Thus, animal of vegetable sponges which are hard and scratchy when dry and require water for plasticization are outside the scope of the invention. However, the polymer making up the fabricated network can be synthetic (e.g., polyethylene), naturally occurring (e.g., cellulose) or a hybrid (e.g., cotton/polyester).

By the term “network” is meant that the component structural elements (e.g., polymer fibers) making up the network are connected at regular, identifiable and reproducible connection points. These connection points can be maintained or “bonded” by chemical, thermal or mechanical (e.g., friction) means. Without wishing to be bound by theory, one of the ways the FPN functions in the invention is by “cushioning” the lathering composition and reducing its intimate contact with “standing water” (e.g., water left in a soap dish). In order to provide this protective cushioning effect, the network should be resilient (e.g., a three dimensional network of bonded fibers) and not simply a dilute dispersion (e.g., a suspension of discrete fibers).

Fabricated polymer networks suitable for the invention must first and foremost be suitable for frequent use as a cleansing implement in showering and bathing: they should not be scratchy or highly abrasive. Thus, soft diamond-mesh sponges of the type described in U.S. Pat. No. 5,144,744 to Campagnoli and commonly known as a pouf or a puff and related networks can be employed.

One suitable and preferred FPN is 3-dimensional non-woven material also called a “batting layer”, having a length (i.e. the major axis) and width (i.e. the minor axis) oriented in the x-y plane and a height oriented along its z axis. Non woven FPN useful for the present invention can range in basis weight from about 25 g/m² to 1000 g/m²

The non-woven FPN contains a large number of fiber-to-fiber bonds. Such continuous networks of bonded fibers are achieved by using one or a combination of chemical or thermal bonding. The batting layer may advantageously have from about 0.25 to about 7 or more fiber to fiber bonds per cubic millimeter. Preferably, the batting layer has about 0.5 to 5 fiber to fiber bonds per cubic millimeter and most preferably has a minimum of about 1 to 3 fiber to fiber bonds per cubic millimeter. Such fiber bonds may be quantified using art recognized or equivalent techniques such as the method described below.

Suitable non-wovens are comprised of synthetic and/or natural fibers converted into continuous networks by conventional, well-known non-woven, woven or knit processing systems or combinations thereof. Generally well known non-woven processing systems transform fibers and filaments directly into useful cohesive structures with adequate strength that are not manufactured via knitting or weaving. Useful synthetic fibers include but are not limited to polyethylene, polypropylene, polyester, low-melt polyester, viscose rayon, polylactic acid and polyamide and blends/combinations thereof and the like. Further examples of synthetic materials useful as components in the present invention include those selected from acetate fibers, acrylic fibers, cellulose ester fibers, and methacrylic fibers. Examples of some of these synthetic materials include acrylics such as Acrilan®, Creslan®, and the acrylonitrile-based fiber, Orlon®; cellulose ester fibers such as cellulose acetate, Arnel®, and Acele®; polyamides such as Nylons (e.g., Nylon 6, Nylon 66, Nylon 610 and the like); polyesters such as Fortrel®, Kodel®, and the polyethylene terephthalate fibers, Dacron®.

Additionally synthetic fibers used herein can be described as staple and continuous filaments including any blend thereof. Non-limiting examples of natural materials useful in the fibrous assembly in the present invention are silk fibers, keratin fibers and cellulosic fibers. Non-limiting examples of keratin fibers include those selected from wool fibers, camel hair fibers, and the like. Non-limiting examples of cellulosic fibers include those selected from wood pulp fibers, cotton fibers, hemp fibers, jute fibers, flax fibers, viscose fibers (rayon) and mixtures thereof. Additionally fibers used herein may include multi-component fibers or combinations thereof. Useful fiber deniers included herein range from about 1 denier to 20 denier including any combinations within this range.

With respect to manufacturing methods for non-wovens useful in the present invention, fibers are separated, oriented and deposited on a forming or conveying surface. Methods used to arrange or manipulate fibers described herein into a fibrous assembly include but are not limited to carding/garnetting, airlay, wetlay, spunbond, meltblown, vertical lapping or any combination/iteration thereof and the like. Cohesion, strength and stability may be imparted into the fibrous assembly via a bonding mechanism that include but are not limited to needlepunching, stitch bonding, hydroentangling, chemical bonding and thermal bonding and any combination/iteration thereof and the like. Fibers that comprise a fibrous structure/assembly may also be used that are not chemically, and thermally bonded to one another to supplement the continuous bonded network of the inventive bar. Such structures that form a plurality of fiber to fiber contacts are all well suited for the present invention.

Some preferred embodiments of useful non-woven FPN include vertical lapped non-wovens, which can be further described as having a given number of pleats per linear unit, i.e., pleats per cm. In this regards, pleats per cm is defined as the number of folds present in a cm of non-woven. This can be measured by placing two marks a fixed distance apart, e.g., 2.54 cm in the machine direction of the non-woven. Subsequently, a count of the number of folds between the two marks is taken. The resultant count divided by the length between markings is taken as pleats per cm. A suitable high bulk corrugated non-woven fabrics are described in U.S. Pat. No. 3,668,054 to Stumpf issued on Jun. 6, 1972; and U.S. Pat. No. 4,576,853 to Vaughn et al. Issued on Mar. 18, 1986; which are incorporated in their entirety by reference herein.

There are a variety of other ways that pleats can be arranged within the FPN to enhance its resiliency and usefulness as illustrated below.

In one arrangement, the non-woven network is a corrugated bulky fabric that has pleats oriented substantially perpendicularly to the x-y plane of the fibrous bar. The x-y plane is defined as the plane of largest surface of the article, i.e., the surface that mainly comes in contact with the skin during cleansing. Preferably there should be about 2.5 pleats per cm to about 15 pleats per cm, i.e., about 1 to 6 pleats per inch. Generally, the pleats will adhere together either through the use of an adhesive or by entanglements.

In another arrangement the non-woven network is a corrugated bulky fabric that has a plurality of discrete peaks. The peaks form a 3 dimensional pattern where the major axis of the peaks is substantially aligned with the z axis of the fabric, i.e., the axis that is oriented substantially perpendicularly to the x-y plane of the fibrous bar. Preferably the number of peaks per square cm is in the range of about 0.25 to about 3 peaks per square cm. Again adhesive or entanglement is generally used to reinforce the corrugated structure.

In another corrugated arrangement, the bulky fabric has a polygonal regular or irregular 3 dimensional honeycomb-like structure of approximately cylindrical cells. Here the major axis of each cylindrical cell of the honeycomb-like structure is oriented substantially perpendicularly to the x-y plane of the fibrous bar.

In yet another corrugated variant, the bulky fabric has a plurality of attached layers oriented substantially perpendicularly to the x-y plane of the cleansing article. Here, the attached layers can be arranged in an arbitrary pattern composed of one or more of spiral, wavy or folded arrangement(s).

Another type of fabricated polymer network is a soft sponge formed from a woven material especially a soft diamond mesh polymeric scrim (a light-weight, open woven fabric). An example of one type of sponge is prepared from extruded tubular netting mesh, which is composed of smooth, flexible polymeric material. Extruded tubular netting mesh of this type, and particularly those prepared from polyethylene are readily available in industry.

The polymeric mesh sponge comprises a plurality of plys of an extruded tubular netting mesh prepared from a flexible polymer, preferably of the group consisting of addition polymers of olefin monomers, and polyamides of polycarboxylic acids and polyamines.

One way such tubular netting can be employed is to form a series of pleats by repeatedly folding the tube to form a 3-dimensional pad that can fit within a mold used to fabricate the cleansing article. Although the individual pleats can be unsecured, the “pad” so formed will unravel as the fibrous bar is used and the lathering composition dissolves. Preferably, however, the pleats are secured by some type of bonding or closure to form a permanent 3-dimension pad or batt.

The bonding can be via thermal treatment (spot or strip welded) or by the application of adhesive (e.g., hot-melt). Alternatively, the pleats can be secured by a weaving or punch process or by any other suitable closure known in the art.

Examples of batts formed by pleating soft diamond mesh scrim are described in U.S. Pat. No. 5,412,830 to Girardot et al incorporated by reference herein.

In the non-woven bonded or woven FPN described above, some or all of the individual fibers may be water-soluble/water-dispersible, i.e., the fibers disintegrate or dissolve in water. Suitable materials for water-soluble/water-dispersible fibers include, but are not limited to, polyethylene oxide (“PEO”), blends of PEO and polypropylene as taught in United States Patent Application 2002/022691 A1, hereby incorporated by reference. Other examples include polylactic acid fibers sold under the tradename LACTRON® by Kanebo, polysaccharides sold under the tradename LYSORB® available from Lysac Technologies Inc., and polyvinyl alcohol such as those sold under the tradename KURALON K-II available from Kuraray Co., Ltd.

Another type of FPN is open cell foam fabricated from polyurethane, modified polyurethane or coated polyurethane. Although not physically a fibrous structure, the characteristics of open cell foam, especially reticulated open cell foam (cell faces are essentially absent), have many aspects in common with non-woven fiber networks. As such, FPN formed from open cell polyurethane foams are included in the scope of “fibrous cleansing bars”. Such foams are available in reticulated or non-reticulated forms. Of these forms flexible, reticulated, open-cell foams having a density between about 0.02 gm/cm³ to about 0.03 gm/cm³ are particularly suitable because they are soft, have a high void volume and are readily incorporated in the lathering composition.

Modified polyurethanes include for example hydrophilic polyurethane formed by reacting an isethionate-terminated prepolymer formed from a hydrophilic polyol ether polyol, e.g., polyoxyethylene polyol and a polyisocyanate and with a water reactant. Such hydrophilic polyurethanes are described in U.S. Pat. No. 4,137,200.

As was the case of FPN based on fiber assemblies described above, synthetic sponges like open-cell polyurethane foams can be pleated or corrugated in a variety of patterns. This can be accomplished by any suitable post-treatment such a compression thermal bonding. However, a more practical approach is by the direct molding of the foam in the shape and texture desired.

Regardless of its specific structure, the fabricated polymer network of this invention has a substantially red color. A variety of color systems can be used to characterize the color of an object. These include for example the well-known Munsell, CIE and Hunter Systems. Three components contribute to color: hue, saturation and lightness or brightness. Hue designates a spectral color, e.g., green.

Saturation is a measure of the extent of dilution of the spectral color with achromatic light (which can be regarded as consisting of a mixture of black and white components, e.g., gray). The greater the saturation the less is the dilution with achromatic light.

Lightness or brightness which is related both to overall intensity of light is a function of illuminance (how and how strongly the object is illuminated) and its reflectivity (or transmittance). The lower the lightness value the darker the color appears. Lightness is independent of hue or saturation and for an achromatic surface (no dominant hue) defines a gray scale.

The system used herein to define a color space is the CIE L*a*b* system. In this variant of the CIE color system, lightness/darkness is measured by the “L* value” which is dimensionless and runs from 0 to 100. Hue and saturation are measured by the values of a* (+values red, −values green, higher the absolute value the more saturated the color) and b* (+values yellow, −values blue, higher the absolute value the more saturated the color). When a*=b*=0, the value of L* spans the achromatic gray scale.

The term black strictly refers to the absence of color (achromatic) and perfectly black is defined as L=0. In the context of the current invention the term “substantially black” refers to a fabricated polymer network that is either achromatic (a*=b*≈0) or has a perceivable hue provided that in ether case, the lightness as measured by the CIE L* value is less than about 50, preferably less than about 30 and most preferably less than about 25. Such networks are perceived to have a similar visual quality described as a very dark, close to black color.

A preferred embodiment is a FPN that is achromatic and has a CIE L* value in the appropriate range, i.e., less than about 20.

FPN that have a green or blue hue are also suitable provided their CIE L* value is sufficiently low. The L* value required to achieve the desired visual darkness to function optimally, i.e., mask discoloration of the lathering composition depends, however, on the specific hue and saturation of the color. It has been found through experiment that the lower the saturation, the higher the L* threshold to achieve a sufficiently dark network.

Non-limiting examples of CIE L*, a*, b* color combinations that yield fabricated polymer networks having preferred substantially black colors are:

-   -   Blue Hue     -   a*˜0; b*˜−20; L*<20, preferably <15     -   a*˜0; b*˜−40; L*<10, preferably <5     -   Green Hue     -   a*˜0; b*˜−20; L*<20, preferably <15     -   a*˜0; b*˜−40; L*<10, preferably <5     -   Achromatic—(true black)     -   a*˜0; b*˜0; L*<15, preferably <10

In principle any of the acceptable FPN forms can be colored substantially black utilizing any of a variety of safe coloring methods known in the art provided that the colorant is stable in the presence of prolonged contact with the surfactant based lathering system.

For PFN based predominantly on thermoplastic polymer fibers such as polyolefins (e.g., polypropylene and polyethylene) and polyesters (polyethylene terephthalate) a commonly used and a preferred coloring technique is the incorporation of a colorant within the fiber during fiber manufacture, i.e., in the melt. This is generally accomplished by utilizing either a dispersed pigment or a colorant that is soluble in the molten polymer.

For dispersed pigment, a dispersion of the pigment is formed in an appropriate vehicle such as low-density polyethylene in the case of polypropylene to form a color additive pre-dispersion. This color additive is uniformly mixed with the molten polymer prior to formation of the fiber.

When polymer-soluble colorants are employed, these are typically added directly to the molten polymer. These process yields a highly color-fast fiber and ultimately a highly color-fast FPN.

Both inorganic and organic pigments can be used to form the pigment pre-dispersion in the above described process. Carbon black is a preferred example of a black pigment and is available in particle sizes that cover a range of denier—even microfibers. Non limiting examples of suitable organic pigments are stabilized copper phthalocyanine pigments for blue hues, and halogenated copper phthalocyanine pigments for green hues and a dioxazine for a violet hue.

Examples of polymer soluble colorants are for polyesters phthalocyanines such as solvent blue 67; perinones such as solvent red 135; and anthraquinones such as pigment yellow 147, and 163.

A second suitable but less preferred method of coloring is the post-coloring (commonly called dyeing) of the fabricated polymer network, e.g., the non-woven batt, after it is formed. Any suitable dyeing process can be utilized provided that it leads to an FPN that is color-stable in the presence of prolonged contact with the surfactant based lathering system.

For hydrophobic synthetic based FPN such as polyester based networks, disperse dye systems are commonly used. Disperse dyes are in fact generally nonionic water-insoluble pigments and lakes. Other types of dyes, e.g., direct dyes are more suitable for FPN containing more hydrophilic fibers such as cotton or NYLON

Preferably, for suitable lather generation of the inventive cleansing article, the density and therefore porosity (P) are important. Porosity can be defined as the volume fraction of air to polymer within a given FPN. Porosity can be expressed using following equation:

${P = \frac{\rho_{f} - \rho_{w}}{\rho_{f}}},$ where ρ_(f) is fiber (or polymer) density (g/cm³) and ρ_(w) is FPN density (g/cm³). Note that the FPN density is based on the apparent thickness of the fabricated network structure. Preferably, the FPN of the present invention should display porosity in the range of from about 0.95 to 0.9999.

Another advantageous material property is the resiliency of the FPN assembly used in the present invention. Specifically, Percent Energy Loss is a desirable parameter as it describes the resilience of the network to an applied load. % Energy Loss is calculated as follows:

${{\%\;{EnergyLoss}} = {\left\lbrack \frac{J_{T} - J_{R}}{J_{T}} \right\rbrack*100}},$ where J_(T), is the Total Energy required to compress the FPN to a 100 gram load and J_(R) is the Recovered Energy during one compression cycle (see Energy Loss Test Method described below). Lower energy loss is seen to correspond to a more resilient network. Preferably, FPN of the current invention have percent energy loss values ranging from about 5% to 50%. Networks having this level of resiliency are also preferred because they have been found to be more effective in the cushioning process described above.

Another useful property of the FPN is air permeability. Air permeability preferably is in the range of about 200 to 900 cubic ft/sq. ft/min (about 60 to about 275 m³/m²/min), more preferably of about 300-700 cubic ft/sq. ft/min (about 90 to about 212 m³/m²/min). Note that 1 cubic ft/sq. ft/min is equal to 0.304 m³/m²/min. Air permeability may be measured using the methodology described below

Lathering Composition

The lathering composition forms a contiguous solid or semi-solid phase which extends throughout the void volume of the fabricated polymer network which it at least partially encompasses. By contiguous is meant that the lathering composition is not simply trapped as isolated pools within the pores of the network as would be the case for a scrub or cleaning pads or filled sponge but rather is a continuous phase running throughout the at least partially encompassed FPN.

The lathering composition comprises the majority of the cleansing article by weight. Thus, the ratio of the weight of the lathering composition to weight of the FPN is in the range from about 30 to 1 to about 2000 to 1, preferably about 50 to 1 to about 500 to 1, and most preferably about 75 to 1 to about 250 to 1.

The lathering composition is preferably a solid of a hardness typical of toilet soaps (often characterized by the term “soft solid”) or a semi-solid elastic material that has an sufficient yield value to retain its shape and to be self supporting. In contrast, viscous pastes that are typically used in scrub or cleaning pads or filled sponge are outside the scope of the present invention.

When the lathering composition is in the form of a solid the composition should have a hardness value measured at a temperature at 25° C. of at least about 15 lbs/in² (103.4 kPa), preferably at least about 20 lbs/in² (139 kPa), and more preferably greater than about 25 lbs/in² (172.4 kPa) as measured by the Cylinder Impaction Test described in the Evaluation Methodology section below. To convert to SI units 1 lbs/in² is equal to 6.895 kPa.

The lathering composition can also be a semi-solid, preferably an elastic semi-solid. The term semi-solid as used herein designates structures that in the absence of a rigid container can keep the shape in which they have been molded or formed for long periods of time: typically days to months. However, they may be deformed and often exhibit viscoelastic behavior in shear deformation.

Semi-solids useful as the lathering composition of the present invention should have a yield stress expressed as the force per unit area required to cut or fracture the semi-solid composition. Generally, the composition of the present invention have a yield stress that is greater than about 10 kPa, preferably greater than about 15 kPa and most preferably greater than about 20 kPa.

By the term elastic is meant that the composition substantially returns to its original shape after a force is applied for a set time and then removed. Specifically, the surface of the lathering composition when compressed to 80% of its thickness and held for 1 minute should be capable of returning to within about 5% of its original thickness within about 30 seconds.

The elasticity of the composition can be characterized by its elastic modulus, which is defined in the present context as the ratio of the force acting normal to a unit area and the linear displacement produced by this force. An alternative measure of elasticity is the compliance, which is the reciprocal of the elastic modulus, and represents the extent of deformation produced by a unit stress (e.g., pressure) acting normal to the surface of the semi-solid.

The compliance of the foamable composition is expressed as the displacement in millimeters produced by a 1 gram force acting over a 1 square centimeter area of gel. Compliance has units of mm/gm/cm² and can be converted into the SI units of M/Pa by multiplying by the factor 1.02×10⁻⁴.

Since the compliance is a function of applied stress, a compliance at a stress value of 3.95 gm/cm² is a convenient measure for comparison of compositions as this represents the stress provided by a 20 gm force acting over 2.45 cm (1 inch) cylindrical platens (area 5.067 cm²).

When the lathering composition is in the form of an elastic semi-solid, the compliance should be in the range of from about 0.06 to about 1, preferably from about 0.07 to about 0.3 and most preferably from about 0.07 to about 0.2 mm/gm/cm² when measured at a stress value of 3.95 gm/cm².

The lathering composition includes one or more lathering surfactants, color additives and various optional ingredients such as water-soluble solvents, hydrophobic benefit agents, structuring agents, and adjuncts. These components are described below.

A. Surfactants

Surfactant components provide lather and assist in the removal of soil and germs. The surfactant should be sufficiently mild to skin and eyes to be suitable for everyday use in cleaning the body in combination with the fabricated polymer network. A variety of surfactant classes discussed below can be employed in the invention.

Anionic Surfactants

Anionic surfactants may comprise about 2% to about 60%, preferably about 2% about 45% and more preferably about 5% to about 35% by weight of the lathering composition.

Soluble soaps are one suitable type of anionic surfactant. Soluble soap is defined as a soap or soap blend having a Krafft point less than or equal to about 40° C. The soluble soap(s) can be selected from the chain length of C₆-C₁₄ saturated fatty acid soap(s) and C₁₆-C₁₈ unsaturated and polyunsaturated fatty acid soap(s) or a combination of these fatty acid soaps. Here the Krafft point of the soap is defined as the temperature at which the solubility of the soap rises sharply. These soluble soaps can be derived from coco fatty acid, Babasu fatty acid, palm kernel fatty acid and any other source of unsaturated fatty acid including tallow and vegetable oils and their mixtures. The soap may be prepared from coconut oils in which case the fatty acid content of C₁₂-C₁₈ is about 85% with C₁₂-C₁₄ species predominant. In addition to specific “soluble” soap, additional soap(s), which may not be as soluble, may be used. These soap components are here referred to as insoluble soaps. Such soaps are typically formed from saturated fatty acids having C₁₆-C₁₈ saturated hydrocarbon chains, The insoluble soap components can for example, be in the range of 5-20% as a structurant for the lathering composition.

The term “soap” is used here in its popular sense, i.e., the alkali metal or alkanol ammonium salts of aliphatic alkane- or alkene monocarboxylic acids. Sodium, potassium, mono-, di- and tri-ethanol ammonium (TEA) cations, or combinations thereof, are suitable for purposes of this invention. In general, sodium soaps are used in the compositions of this invention, but from about 1% to about 25% of the soap may be potassium or TEA soaps. Overall the soap(s) useful herein are the well known alkali metal salts of natural of synthetic aliphatic (alkanoic or alkenoic) acids having about 12 to 22 carbon atoms, preferably about 12 to about 18 carbon atoms. They may be described as alkali metal carboxylates of hydrocarbons having about 12 to about 22 carbon atoms. The soaps may contain unsaturation in accordance with commercially acceptable standards. Excessive unsaturation is normally avoided to minimize the color and odor issues.

Soaps may be made by the classic kettle boiling process or modern continuous soap manufacturing processes wherein natural fats and oils such as tallow or coconut oil or their equivalents are saponified with an alkali metal hydroxide using procedures well known to those skilled in the art. Alternatively, the soaps may be made by neutralizing fatty acids, such as lauric (C 12), myristic (C 14), palmitic (C 16), or stearic (C 18) acids with an alkali metal hydroxide or carbonate or alkanolamide.

The lathering composition of the present invention may contain one or more anionic synthetic surfactants (commonly called syndets).

The anionic surfactant may be an aliphatic sulfonate, such as a primary alkane (e.g., C₈-C₂₂) sulfonate, primary alkane (e.g., C₈-C₂₂) disulfonate, C₈-C₂₂ alkene sulfonate, C₈-C₂₂ hydroxyalkane sulfonate or alkyl glyceryl ether sulfonate (AGS).

The anionic may also be an alkyl sulfate (e.g., C₁₂-C₁₈ alkyl sulfate) or alkyl ether sulfate such as alkyl ethoxy (1-10 EO) sulfate and an alkyl glyceryl ether sulfate or a mixture of the two.

The anionic may also be C₁₀ to C₁₈, preferably C₁₂ to C₁₄ alkyl sulfosuccinates; alkyl and acyl taurates, alkyl and acyl sarcosinates, fatty N-acyl amino acid salts, sulfoacetates, C₈-C₂₂ alkyl phosphates, alkyl phosphate esters and alkoxyl alkyl phosphate esters, acyl lactates, C₈-C₂₂ monoalkyl succinates and maleates, sulphoacetates, and acyl isethionates, and the like.

Sodium and ammonium alkylethoxy (1-5 EO) sulfosuccinates, especially lauryl ethoxy (3 EO) sulfosuccinate are also useful.

Especially useful acy isethionates are C₈-C₁₄ acyl isethionates that are prepared by reaction between alkali metal isethionate with mixed aliphatic fatty acids having from 8 to 12 carbon atoms and an iodine value of less than 20.

Amphoteric Surfactants

One or more amphoteric surfactants may be used in this invention. Such surfactants include at least one acid group. This acid group may be a carboxylic or a sulphonic acid group. They also include quaternary nitrogen and therefore are quaternary amido acids.

A further possibility is that the amphoteric surfactant is a sulphobetaine. A preferred sulfobetaine is cocoamidopropyl hydroxy sultaine

Amphoacetates and diamphoacetates are also intended to be covered in the zwitterionic and/or amphoteric compounds which are used such as e.g., sodium lauroamphoacetate, sodium cocoamphoacetate, and blends thereof, and the like.

A preferred amphoteric surfactant is an alkyl betaine such as cocobetaine. or an alkylamidoalkyl betaine such as cocoamidoproyl betaine or mixtures thereof.

When present, the level of amphoteric surfactant can be in the range from about 1% to about 15%, preferably from about 1% to about 10%, and most preferably from about 1.5% to about 8%.

Nonionic Surfactants

One or more nonionic surfactants may also be used provided they do not interfere with lathering or overall skin mildness or induce eye irritation. When present, nonionic surfactants may be used at levels from 1% to about 10%, preferably about 1% to about 5%, and most preferably from about 0.5% to about 4% by weight.

The nonionics which may be generally used include the reaction products of compounds having a hydrophobic group and a reactive hydrogen atom, for example aliphatic alcohols, acids, amides with alkylene oxides, especially ethylene oxide either alone or with propylene oxide. Examples of nonionic surfactants detergent compounds are (C₁₂-C₂₂) fatty alcohol-ethylene oxide condensates. However, alkylphenol-ethylene oxide condensates should be minimized and preferably be avoided because of their defatting properties.

The nonionic surfactant may also be a C₁₀ to C₁₆, preferably C₁₂ to C₁₄ fatty alkanol amide such as cocamide MEA. These nonionics are particularly effective foam boosting agents.

Other types of suitable nonionic surfactants are derived from saccharides or polysaccharides. These include C₁₀ to C₁₈ alkyl glycosides and alkylipolyglycosides which can be broadly defined as condensates of long chain alcohols, e.g., C8-30 alcohols, with sugars or starches, i.e., glycosides or polyglycosides.

Other useful nonionic surfactants include polyhydroxy fatty acid amide surfactants; specific examples of which include glucosamides such as coconut alkyl N-methyl glucosamide.

Other examples of nonionic surfactants are amine oxides such as dimethyldodecylamine oxide.

Cationic Surfactants

One or more cationic surfactants may also be used in the inventive foamable composition. Advantageously cationic surfactants are used from about 0.5 to about 10%, preferably from about 0.5% to about 5% by wt.

Examples of cationic surfactants are the quaternary ammonium compounds such as alkyldimethylammonium halides

Other suitable surfactants which may be used are described in U.S. Pat. No. 3,723,325 to Parran Jr. titled “Detergent Compositions Containing Particle Deposition Enhancing Agents” issued Mar. 27, 1973; and “Surface Active Agents and Detergents” (Vol. I & II) by Schwartz, Perry and Berch, both of which are also incorporated into the subject application by reference.

In preferred embodiments of the invention the surfactant system and optional water soluble organic solvent (see below) are chosen so as to provide a translucent or transparent lathering composition. The meanings of “transparent” and “translucent” are those generally employed and are in accordance with usual dictionary definitions. Thus, a transparent soap is one that, like glass, allows the ready viewing of objects behind it. A translucent soap is one which allows light to pass through it but the light may be so scattered, as by a very small proportion of crystals or insolubles that it will not be possible to clearly identify objects behind the translucent soap.

Of course, even “transparent” objects, such as glass, can prevent seeing through them if they are thick enough. For the purpose of this specification, it will be considered that the soap section tested for transparency or translucency is approximately 6.4 mm. thick (¼ inch). Thus, if one is able to read 14 point bold face type through a ¼ inch or 6.4 mm thickness of soap, the soap qualifies as transparent. If one can see light through such a sample thickness but can't read the type print, the soap is only translucent. Of course, all transparent soaps also qualify as translucent (considering translucent as generic). Other tests for transparency and translucency, including the translucency voltage test mentioned in U.S. Pat. No. 2,970,116, may also be employed.

The level of translucency can be quantified by the measurement of light transmittance using for example a UV-vis spectophotometer. For example, different samples of the lathering compositions of a constant thickness, e.g., 6.4 mm or 10 mm are prepared. The % transmittance of light, from 400-800 nm, through this sample is measured. In opaque soaps, i.e., non-translucent, the transmittance of light through a one centimeter sample is zero while in translucent soaps a progressively larger amount of light is transmitted. Transparent means that 14 print font can be read through the sample of the selected controlled thickness.

Transparent lathering compositions can be prepared with a variety of surfactant compositions as is well known in the art. Generally this involves the minimization of the size of solid domains (amorphous or crystalline), e.g., solid soap that serve as scattering centers through the use of crystallization inhibitors, intensive mixing or a combination of these. Additionally, the refractive index difference between the continuous generally aqueous phase and any disperse solid phase present in the composition can be reduced through the use of highly water organic soluble solvents such as alcohols and polyols, e.g., sorbitol. Generally a combination of approaches is employed.

It has been found that translucent or transparent lathering compositions can be made darker in color without using excessive levels of colorants and also exhibit greater enhancement of coloration when using the substantially black FPN described above. Without wishing to be bound by theory, it is believed that opaque lathering compositions optically dilute the colorant with a scattered white light component which effectively raises the reflectivity and thus the lightness value and also masks the effect of the darkly colored FPN.

Transparent compositions are preferred because they require the least level of colorant especially when they are colorless. In fact it has been found that colorant is not always required in transparent lathering compositions especially when the FPN is very dark (L*<15) and composed of a high density of fibers.

B. Colorants

The lathering compositions of the present invention can be either transparent, translucent or opaque.

When the lathering composition is transparent, it has been found that the inclusion of colorant is not always required although colorant can be added to enhance the appearance of the finished cleansing article (the fibrous bar) for example the overall color intensity.

In contrast, opaque or translucent lathering compositions require colorant to achieve fibrous bars that are aesthetically pleasing and remain so during storage and especially during use. Ideally, the color of the opaque or translucent lathering composition should match the color of the fibrous network especially its lightness sufficiently closely that the cleansing article viewed as a whole does not appear inhomogeneous.

For translucent or opaque lathering compositions the preferred color is substantially red as defined above in terms of the chromaticity coordinates L*a*b*.

One embodiment of the invention is a fibrous bar in which the fabricated polymer network and the lathering composition are substantially color-matched. By the term “substantially color-matched” is meant that the chromaticity values of the FPN and the lathering composition are sufficiently close so that the fibrous bar appears uniform, e.g., the lathering composition coordinates visually with the FPN.

To match the color of the lathering composition to the FPN, any systematic optimization procedure can be employed. For example, a matrix of test composition incorporating different levels of dyes can be prepared and their CIE color coordinates measured. A three dimensional regression analysis can be performed correlating dye concentration with the color difference between the test lathering compositions and the target color (e.g., that of the FPN being employed). A useful measure of color difference is ΔE defined as ((ΔL*)²+(Δa*)²+(Δb*)²)^(1/2). In this procedure the colorant mix is chosen by extrapolation to give ΔE≦ΔE_(crit) where ΔE_(crit) represents the minimum difference required to produce a fibrous bar that is sufficiently homogeneous in appearance based on consumer requirements and of the desired color.

The lathering compositions of the present invention are darkly colored and substantially black. The system used herein to define a color space for the lathering composition is again the CIE L*a*b* system. Utilizing this color system In the context of a lathering composition, the term “substantially black” refers to a solid or semi-solid lathering composition that is either achromatic (true black) or has a perceivable hue provided that in ether case, the lightness as measured by the CIE L* value is less than about 60, preferably less than about 40 and most preferably less than about 20. Such compositions are perceived to have a similar visual quality described as a very dark, close to black color.

Preferred embodiments are lathering composition that are either achromatic (close to a*=b*≈0) or have a green or blue hue provided the CIE L* value is sufficiently low. The L* value required to achieve the desired visual darkness to provide unique and desirable appearance depends, however, on the specific hue and saturation of the color. It has been found through experimentation that the lower the saturation, the higher the L* threshold to achieve a sufficiently dark color.

Non-limiting examples of L*,a*,b* combinations (“color coordinates”) providing a suitable color to the lathering compositions are:

Dominant hue L* a* b* Blue 51.2 −22.2 −36.1 35.5 −10.4 −45.5 Green 55.6 −49.3 45.1 40.3 −40.6 1.1 Achromatic 19.1 0.47 −1.84

A variety of dyes and pigments (especially lakes) are suitable for coloring the lathering composition and various combinations of suitable colorants for soap and toilet bars can be employed. Suitable dyes include the various FD&C dyes such as FD&C Blue #1 and #2, Yellow #5, #6 and #10, Red #27, #30 (lake) #3 (dye and lake) and #40, Green #3, #5, #6 and 8, Violet #2, and their mixtures.

Other examples of colorants are ultramarine blue (medium and dark grades), ultramarine violet, black oxide, and red oxide (less preferred but useful as part of a colorant blend), yellow oxide, hydrated chromium oxide and chromium oxide green, brown oxide and their mixtures

Colorants from vegetable and mineral sources can also be employed. Non-limiting examples include: green clay (french)/montmorillonit, green tea, hemp seed oil (unrefined), ground henna, indigo root; kelp, oolong tea extract palm or palm kernel oils (unrefined), poppy seeds, rattanjot safflower petals, sage, sea clay, seaweeds, spirulina/blue-green algae, tumeric, yellow illite (clay) and their mixtures with natural or other types of colorants.

Various color adjuncts and modifiers can also be employed. For example polymers such those incorporating -alkyl-2-oxazolidinone moieties can be utilized to form insoluble organic from a water-soluble organic dye as described in U.S. Pat. No. 4,533,484 to Walles et al.

Preferred colorants include combinations of FD&C Blue #1, FD&C Red #40, FD&C Yellow #5, and FD&C Yellow #6.

The level of colorant depends on the composition of the lathering composition, e.g., its opacity and intrinsic color. A level of colorant from about 0.1% to about 1%, preferably from about 0.1% to about 0.5%, and most preferably from about 0.2% to about 0.4% based on the weight of the lathering composition is generally acceptable.

C. Optional Ingredients

Water Soluble Organic Solvents

The term “water soluble organic solvent” is used herein to describe a highly water soluble organic molecule that is innocuous to the skin in aqueous solution and can be used to manipulate the solubility of other organic molecules, alter the pliability, the clarity or other properties of the composition. The water soluble organic solvent can be a liquid or a solid in its pure state. By highly water soluble is meant a water solubility in excess of 10% by weight, preferably in excess of 20% by weight and most preferably a solubility in excess of 50% by weight in water at room temperature. Preferred organic solvents are humectant solvents which effectively reduce water activity and thus retard water evaporation. It has been found that humectant solvents are useful in preventing discoloration of darkly colored fibrous bars that are based on translucent or transparent lathering compositions. Preferred humectant solvents are glycerol, sorbitol and low molecular weight polyethylene oxide.

One group of suitable water soluble organic solvents for use herein include C₁-C₁₀ mono- or polyhydric alcohols and/or their alkoxylated ethers. In these compounds, alcoholic residues containing 3 to 6 carbon atoms are particularly preferred. Examples of this group include ethanol, isopropanol, n-propanol, butanol, propylene glycol, ethylene glycol monoethyl ether, hexylene glycol, glycerol, sorbitol and mixtures thereof.

Another group of suitable water soluble organic solvents include polyalkylene oxides having a molecular weight below about 1000 Daltons. These include polyethylene oxide, polypropylene oxide, and random or block copolymers of ethylene oxide and propylene oxide alone or also containing butylene oxide and/or a terminal alcohol group having about 2 to about 8 carbon atoms.

Water soluble organic solvents can also be sugars and low molecular weight polysaccharides (<25 kDaltons) such as sucrose, glucose, polydextrose, and maltodextrin.

Another type of water soluble organic solvent is an alkanolamine such as triethanolamine.

The water soluble organic solvent(s) may be present at a level of from 0 to about 50%, preferably from about 2 to about 35% and most preferably from about 2% to 30% based on the total weight of the lathering composition.

Structuring Agents

Structuring of the lathering composition is often provided by the surfactants themselves. For example, interlocking networks of macroscopic crystals of soap may provide the structure. Such compositions are described in U.S. Pat. No. 5,340,492 to Kacher et al issued Aug. 23, 1994, and in U.S. Pat. No. 6,363,567 to Nadakatti et al issued Apr. 2, 2002 both of which are incorporated herein by reference.

Another example of surfactant structured compositions are the “coagels” formed by networks of nano-crystals or by an isotropic liquid crystalline phase, e.g., cubic or gel phases. Nonlimiting examples of such compositions are described in U.S. Pat. No. 4,988,453 to Chambers et al issued Jan. 29, 1991 and U.S. Pat. No. 5,310,485 to Hill et al issued May 10, 1994.

However, in some circumstances additional structuring agents prove useful and can be employed in the invention at levels between about 0.5% and about 15% by weight, preferably between about 1% and about 10% by weight. Such structurants include saturated, (C₈-C₁₈) fatty acids or ester derivatives thereof, substituted fatty acids, long chain, preferably straight and/or branched long chain, saturated, (C₁₃-C₂₄) alkyl alcohol, or C₁₉-C₂₄ alkenyl alcohols or mixtures thereof. Non-limiting examples include stearic acid, 12-hydroxystearic acid and cetostearyl alcohol. Non-limiting examples of the effective use of such structurants in thermosetting compositions are disclosed in U.S. Pat. No. 6,458,751 to Abbas et al issued Oct. 1, 2002 and incorporated by reference herein.

Other useful structuring components are mono- di- and triglycerides especially hydrogenated glycerides such a hydrogenated cotton seed oil.

Mixtures of long chain fatty amines with anionic surfactants alone or admixed with fatty acid or fatty alcohol can also be employed as structurants.

Another class of useful structuring agents for semi-solid compositions is thermosetting polymers, i.e., polymers that form thermoreversible gels having a specific melting of gelling temperature. These polymers are particularly useful in the formulation of thermosetting elastic compositions. Non-limiting examples of useful polymers that form thermoreversible semi-solids include gelatin, carrageenan, agar, and gellan.

The incorporation of agents that provide some structure to the composition while it is still in the molten state is often very useful in the preparation of compositions that incorporate multiple phases. Such structurants suspend and prevent segregation of dispersed phases before the composition sets. Example of suitable structuring agents for gas bubbles are the PEG alkyl ester and PEG alkyl ethers such as PEG (12) monolaurate. Examples of thermosetting compositions utilizing such suspending agents for highly aerated bars are described in U.S. Pat. No. 5,972,860 to Eshita et al Issued Oct. 26, 1999 and incorporated by reference herein.

Examples of other suitable structurants for suspension of for example, particulate inclusions are synthetic or natural hectorites. A synthetic hectorite, LAPONITE XLG from Laporte is particularly suitable. Examples of thermosetting compositions utilizing such suspending agents for suspending articles such as microcapsules in thermosetting compositions is disclosed in U.S. Pat. No. 6,403,543 to Edmund George issued Jun. 11, 2002.

Other structuring aids can also be selected from water soluble polymers chemically modified with a hydrophobic moiety or moieties, for example, EO-PO block copolymer, hydrophobically modified PEG such as POE(200)-glyceryl-stearate, glucam DOE 120 (PEG 120 Methyl Glucose Dioleate), and Hodag CSA-102 (PEG-150 stearate), and Rewoderm® (PEG modified glyceryl cocoate, palmate or tallowate) from Rewo Chemicals. Other structuring aids which may be used include Amerchol Polymer HM 1500 (Nonoxynyl Hydroxyethyl Cellulose) and hydroxypropyl starch phosphate sold by National Starch and Chemicals.

The lathering composition can optionally contain fillers, which provide body or strength to the composition. Suitable fillers are selected from inorganic minerals such as calcium sulfate, sodium aluminates, and the like; starches, preferably water soluble starches such as maltodextrin and the like and polyethylene wax or paraffin wax, and the like. Fillers may be present in the composition in the range of about 1 to about 15 % by weight, preferably about 1 to about 10% by weight.

Aesthetic and Adjunct Ingredients

A wide variety of optional ingredients can be incorporated in the lathering composition provided they do not interfere with the structuring, in-use properties of the composition (e.g., lather amount and rate), and visual characteristics of the darkly colored, substantially black article. Adjunct ingredients include but are not limited to: perfumes; pearlizing agents, nacreous “interference pigments” such as TiO₂ coated micas; sensates such as menthol and ginger; preservatives such as dimethyloldimethylhydantoin (Glydant XL1000), parabens, sorbic acid and the like; anti-oxidants such as, for example, butylated hydroxytoluene (BHT); chelating agents such as salts of ethylene diamine tetra acetic acid (EDTA) and trisodium etridronate; emulsion stabilizers; auxiliary thickeners; buffering agents; skin conditioning agents such as silicones (e.g., Dimethicone), hydrocarbon (e.g., petrolatum) and cationic polymers (e.g., cationic guars and cellulosics), and mixtures thereof.

Manufacturing and Packaging

The fibrous bars of the invention are preferably made by a melt and pour (also called “melt-cast”) process in which the molten lathering composition is combined with and at least partially encompasses the fabricated polymer network and is then allowed to solidify or gel, i.e., by reducing the temperature to below the melting point.

This process can be carried out in several ways. In one preferred embodiment, the combining step is carried out in a single-use mold where the mold forms all or a part of the package in which the fibrous bar is sold or even stored during use. A description follows.

Two broad types of single-use molds, well known in the art, can be employed. The first is made up of two or more individual parts that are preassembled (press fitted or glued) into a “unitary design” before filling it with the molten lathering composition. In this case, the FPN can be inserted into the mold either before or after the mold is assembled. Here, the molten composition is injected or poured into the mold, and then the mold entry is sealed by either heat sealing or with a separate covering (e.g., a polymer film). Such a mold can be filled either along one of its edges or along its face.

The second type of single-use mold is a “blister pack” formed by shaping a polymer film (e.g., blow molding or stretching over a mandrill) into a cup-like structure. Here, the FPN can be inserted into the mold before or after the molten lathering composition is added. Furthermore, the bottom of the cup can have either a protrusion or well that accommodates a part of the fibrous layer, or can have an elevated or depressed area that provides an indicia or logo to the fibrous bar. Once the blister pack is filled, the pack is sealed and cooled (not necessarily in this order). The sealing is generally accomplished by covering with a polymer, paper or laminated film: sealing provided via some form of adhesive or by heat or pressure sealing.

Either the unitary design or blister pack mold can be subjected to lower temperature cooling to accelerate the setting of the composition. The cooling can be accomplished either in bulk storage (e.g., a refrigerator) or by passage through a cooling chamber such as a cooling tunnel. The single use mold can serve as the final package at point of sale and thus bears printing or a means for hanging or display. Alternatively, the mold can be further wrapped or cartoned.

A second suitable processing route employs a multiple-use mold wherein the fibrous bar is formed and solidified in the mold, released from the mold for further processing. In this case the mold is reused. A disposable mold can also be used to accomplish the same processing ends—the mold being discarded after the article is demolded. In any event, the molten lathering composition is added to the mold by gravity or pressure feeding (injection). The mold can be of such a shape and volume so as to form either a single fibrous bar or it can be a tray, pan, or cylinder so as to form a loaf, log or billet that can be cut into individual articles. Alternatively, the mold can include two or more elements that are joined before the foamable composition is introduced (e.g., by injection under pressure) and then separated after the composition has set to release the article. Such an “injection mold” can form either an individual fibrous bar or a log or loaf that can be cut after demolding. The setting process can be accomplished continuously, for example by chilling the mold, or the molds can be stored for a suitable period of time in a chamber at any temperature below the melting or setting point of the composition and later the article can be demolded.

The FPN can be inserted into the multiple-use mold before or after the molten lathering composition and the mold can also include a recessed area to accommodate part of the fibrous layer. Alternatively, the mold can be partially filled and the foamable composition partially set before the fibrous layer is introduced.

Once set, the fibrous bar is demolded and further processed and packed. For example, the article can be further shaped (e.g., by cutting), wrapped in a film (e.g., shrink-wrapped), cartoned or any combination of such steps.

In either of the manufacturing methods described above, the lathering composition can be partially cooled, for example by means of an in-line heat exchanger before the composition is inserted into the mold and combined with the FPN.

Evaluation Methodology

A. Percent Energy Loss Test Procedure:

Percent Energy Loss describes the resilience of a network to an applied load. A 3.8 cm circular disk of the test FPN is placed between the platens of an Instron Tensile/Compression Testing Machine (e.g. Instron Model No 4501 with load cell (226.98 N load Cell). The platen separation is 31.75 mm. The sample is then compressed at a compression cycle strain rate of 38 mm/min to a maximum load of 100 gm-force (0.98N) using a 5N load cell. The platens are then separated at a recovery cycle strain rate of 38 mm/min.

Total Energy required to compress a sample to 100 grams load, and the Recovered Energy from one compression cycle is determined. The % Energy Loss is then calculated as follows:

${\%{EnergyLoss}} = {\left\lbrack \frac{J_{T} - J_{R}}{J_{T}} \right\rbrack*100}$ % Energy Loss is the resiliency of the FPN i.e. the ability to recover compressive force

-   J_(T)=Total Energy Required to Compress material to 100 grams -   J_(R)=Recovered Energy during one compression cycle     B. Yield Stress—Cheese Cutter Method for Semi-solids

This method measures the yield stress of a composition and is used herein to measure the maximum strength of an elastic semi-solid. This method can also be used to measure the yield stress of the composition, i.e., the lathering composition that includes the fabricated polymer network.

A wire penetrating into the lathering composition with a constant force will come to rest when the force on the wire due to internal stress balances the weight applied to the wire. The stress at the equilibrium point is described as yield stress (σ₀). The procedure is as follows.

A square of test sample (3.2 cm×3.2 cm×5 cm) is positioned on the yield stress device. A 400-grams weight is then attached to the arm of the device. The arm is then lowered such that the wire comes into contact with sample. The arm is then released allowing the wire to penetrate the test sample for 1 minute. The length of wire in the sample is then measured and recorded. The yield stress (σ₀) in kPa is determined from the following equation:

${\sigma_{o} = \frac{0.375\mspace{11mu}{mg}}{1D}},$ where,

-   m=mass of driving wire (mass placed on device plus 56 grams) -   g=gravitational constant (9.8 m/s² -   I=length of wire measured to penetrate the semi-solid after 1 minute     (mm) -   D=diameter of wire (e.g., 0.336 mm)     C. Instron Indentation Test—for Compliance of Elastic Semi-solids

This method is used to measure the compliance (linear displacement per unit of stress at a give stress value (force per unit area)) of elastic lathering compositions. Softer compositions are those which have a greater compliance.

The compliance is computed from measurements of the depth of indentation (displacement) as a function of applied load of a rod into a “block” formed from the semi-solid elastic composition (or a composite that also includes the FPN). The displacement as a function of load is measured using an Instron Model 4501 Universal Testing Instrument.

Two blocks (typically 3.2 cm×3.2 cm×5 cm) of each composition are prepared and equilibrated in an environmental chamber at 21° C. and 50% relative humidity prior to testing. A 2.54 cm diameter indenting plate coupled to the Instron is then pressed against each block at a rate of 25 mm/min and recorded the forces at 50 data points per minute until a compression force of 65 grams is reached. The data is then transformed into the displacement at 5, 10, 20, 30 and 50 grams force applied load. Each block is compressed six times at different locations on the block.

The compliance at each applied stress in computed from: Stress=Load (gm-force)÷Area of identing plate (cm²) Compliance=Displacement of indenting plate (mm)÷Stress (gm/cm²) D. Air Permeability Methodology

The Air Permeability is related to the amount of lather that can be generated by a particular fabricated polymer network. The Air Permeability has been found to directly affect the density and amount of lather that a particular nonwoven material is capable of generating. The Air Permeability values of the present invention were determined using ASTM Method—Designation D 737-96.

Testing Components:

-   1. Test head that provides a circular test area of 38.3 cm 2±0.3%; -   2. Clamping system to secure test specimens; -   3. A clamping ring that minimizes edge leakage; -   4. Air flow controller providing a minimum pressure drop of 125 Pa     (12.7 mm or 0.5 in. of water) across the specimen); -   5. Pressure gauge or manometer having an accuracy of ±2%; -   6. Flowmeter, volumetric counter or measuring aperture to measure     air velocity through the test area in cm 3/s/cm 2 (ft 3/min/ft 2 )     with an accuracy of ±2%; -   7. Calibration plate, or other means, with a known air permeability     at the prescribed test pressure differential to verify the     apparatus; -   8. Means of calculating and displaying the required results, e.g.,     scales, digital display, and computer-driven systems; and -   9. Cutting dies or templates, to cut substrate specimens having     dimensions at least equal to the area of the clamping surfaces of     the test apparatus.

The FPN samples are cut to the appropriate size (size of clamping surface) using a cutting die. The samples are then preconditioned at a standard temperature and humidity, 21° C.±1° C. and 65±2% R.H. Once the samples are preconditioned, they are allowed to reach moisture equilibrium in the standard atmosphere. The test samples are carefully handled to avoid altering the natural state of the samples. They are then place in the test head of the test apparatus, and the test is performed as specified in the manufacturer's operating instructions. The tests are carried out using a water pressure differential of 125 Pa (12.7 mm or 0.5 in. of H₂O). The individual test sample results are recorded in ft³/min/ft² (or 0.304 m³/m²/min in metric units) These results represent the Air Permeabilities of the samples.

E. Fiber to Fiber Bond Determination (for Non-woven FPN)

A 4 mm×25 mm×25 mm section of nonwoven sample is prepared and placed on glass slide and secured with tape (sample slide). A reference glass slide is prepared by placing a 1 mm×1 mm mark on a glass surface. Photomicrographs of the reference slide are taken at a 10× magnification and the length of mark on photo in mm is measured and recorded. Photograph (×5) of the sample slide are then taken under the microscope at 10× magnification. This is repeated for three other samples with each sample done in duplicate. The number of fiber to fiber bonds on each photo is then counted. Using a scale created from the reference slide, the actual area of each sample slide is determined. The number of fiber-to-fiber bonds is divided by the actual area (mm²) and the results finally averaged to provide the Number of Fiber-to-Fiber Bonds/mm³.

Each image can be expressed as a given volume V, using as a thickness one fiber diameter. Assuming perfect fiber packing and no air voids between fibers. Given a porosity (P), where porosity is the volume fraction of fiber to air in a given nonwoven sample, the number of contacts per cubic millimeter for a given nonwoven having porosity P can be calculated as follows.

The Image Volume (V) is given by: Volume (V)=image area (mm²)*fiber diameter(mm)

The Number of Fiber to fiber bonds per mm³ (TC) is calculated from: TC=CP/V where CP is the number of fiber to fiber bonds taken from sample image.

The actual number of fiber to fiber bonds (AC) is then determined from the following equation: AC=TC*(1−Porosity) F. Cylinder Inpaction Test for Hardness/Yield Stress of Solids

A variety of methods are known in the art to measure the hardness of “soft solids” used in, for example, toilet soaps. The most common techniques are the Cylinder Impaction Test which measures the maximum force before yielding and the Penetration Test which measures the penetration of a needle under a constant load. Although the invention is described by parameters that are measured by the Cylinder Impaction Test, this was done for convenience from a manufacturing perspective. The various hardness tests can obviously be inter-correlated.

The Cylinder Impaction Test employs a modified Crush-Test protocol that is used for measuring carton strength. A Regmed Crush Tester was employed.

Samples of the solid lathering composition (typically 8×5×2 cm) at the desired temperature were placed on the lower plate of the tester fitted with a pressure gauge and a temperature probe inserted in the sample approximately 4 cm from the test area. An 89 gm inox metalic cylinder (2.2 cm in diameter (0.784 in) and 3 cm in length (1.18 in)) was placed at a central location on the top of the sample. The upper plate is then lowered to just touch the cylinder.

The top plate was then lowered at a programmed rate of 0.635±0.13 mm/s (0.025±0.005 in/sec). At a certain strain, the sample will yield, bend or fracture and the maximum force expressed as PSI (lbs/inch²) and average sample temperature are recorded. The water content of the sample is measured immediately after the test by microwave analysis. The hardness measurement is repeated a total of 3 times with fresh samples and an average taken. It is important to control the temperature and water content of the sample since hardness is sensitive to both these variables.

G. CIE L*a*b* Measurement Using Macbeth Spectrometer

A Gretag MacBeth COLOR-EYE 7000 was employed to measure the color of fabricated polymer networks, lathering compositions and fibrous bars. Following the instruction manual supplied with the COLOR-EYE 7000, the instrument was calibrated using both a ZERO calibration standard (black tile) and a WHITE calibration standard specific to machine. The calorimeter was then set to read in reflectance mode with an illuminant source chosen as D65 and an observer angle of 10°.

Each sample was measured in triplicate using the following backgrounds. For transparent/translucent samples a white tile background was employed, while the black tile background was employed for opaque samples and the Fabricated Polymer Network, e.g., for a non-woven batt.

H. Soak Test for Bar Discoloration and Residue

Individual plastic tray are filled with a layer of deionized water to a depth of about 0.65-0.7 mm. The trays are fitted with an air-tight cover. Samples of cleansing articles (fibrous bars or lathering composition) are placed in the middle of each tray and covered. Different samples are allowed to equilibrate for the following time periods: 1 hr, 3 hrs, 6 hrs, and 12 hrs.

Individual samples are then removed from trays and immediately evaluated for appearance—comparing the surface exposed to the water soak with the top unexposed surface. The test samples are then placed on paper towels wet side up and allowed to dry in air at room temperature for different periods of time (1 hr. 6 hrs, and 12 hrs) and reassessed for visual appearance.

SPME Analysis of Fragrance Retention

Fragrance retention on skin was measured by Solid Phase Micro Extraction (SPME). A slurry of the test article is prepared by combining 0.5 g of the composition with 1 ml of deionized water in a sealed container and stirring the mixture at about 30 to 35° C. for 30 minutes.

The forearm of a test subject was prewet with water at a temperature of 32° C. after which the entire sample of the slurry is applied with a gloved hand and the slurry was worked into a lather by gentle rubbing for 30 sec. The arm is then rinses for 15 minutes and patted dry with soft absorbent paper.

A closed bulb shaped collection vessel (approximate dimensions 2 cm in diameter by 50 cm high) containing a Supelco SPME Fiber Assembly (30 um DVB/Carboxen/PDMS) is secured in contact with the forearm and perfume in the head space was collected for 30 minutes. The procedure is repeated but after allowing the treated forearm to remain uncovered for 60 minutes.

The SPME fibers were analyzed by gas chromatography using an Agilant Technologies (formerly Hewlett Packard) Model 6890 with Mass Selective Detector Model 5973. A The column an Agilant Technologies number 19091S-433, HP-5MS, 5% Phenyl Methyl Siloxane, 30 m×0.25 mm ID with a 0.25 μm film thickness.

EXAMPLES

The following examples are shown as illustrations of the invention and are not intended in any way to limit its scope.

Example 1 and Comparatives 1-2

The lathering composition used in example 1 and comparatives 2 and 3 is shown in Table 1. The lathering composition in this case is a transparent solid that has a CIE Lightness value L*=25.1.

TABLE 1 Lathering Composition of Example 1 and Comparatives 1-2 COMPONENT (as 100% active) Wt % Stearic acid/palmitic acid blend 14 Coconut fatty acid 9 12 hydroxy stearic acid 3.5 lauric acid 3.06 sodium lauryl sulfate 7.20 Sodium soap (85/15 tallow/cocco) Sodium hydroxide 2.34 Sorbitol 14.5 Polyethylene Glycol (CARBOWAX 200) 5.0 Propylene glycol 10.2 Isopropyl alcohol 1.23 Glycerin 0 HERC Jetine Black (from LCW South 1.5 Plainfield NJ) Minors (e.g., perfume, preservatives, 0.5 etc) Water to 100

Example 1 employs as the continuous fabricated polymer network a 100% polyethylene terephthalate non-woven, whose structure is designated SF-3 (X-87), obtained from Structured Fibers Incorporated, Saltillo, Miss. This non-woven is composed of black polyester fibers (carbon black) and has a CIE Lightness value of L*=12.5. Its other physical characteristics are given in Table 2.

TABLE 2 Characteristics of continuous non-woven used in Example 1 Denier % 4 25 6 75 Fiber Type 100% PET Basis Weight (oz/sq. yd)* 5 Number of fiber to fiber bonds per cubic mm 2.19 Note *Oz/sq. yd = 33.9 gm/m²

To prepare the fibrous bar of example 1, approximately 100-grams of the lathering composition of Table 1 was heated to 65° C. and poured onto the non-woven pad (2 gm-dimensions:9 cm×6 cm×2 cm) contained in a plastic mold. The lathering composition was allowed to absorb and completely permeate the network. The resulting intimately blended lathering composition and FPN was then cooled to about 15° C. at approximately 50% RH until solidified fibrous bar was then removed from the mold.

Comparative 1 was prepared in the same manner as example 1 except that the mold did not contain any polymer network. Thus, approximately 100-grams of the lathering composition of Table 1 was heated 65° C. and poured into an empty plastic mold. The lathering composition was then cooled to about 15° C. at approximately 50% RH until solidified and the cleansing article (bar) was removed from the mold. Comparative 1 is thus a melt-cast soap bar.

Comparative 3 was prepared in the same manner as example 1 except that in place of the continuous non-network a mass composed of approximately 6 den black PET fibers approximately 3.8 cm in length was employed.

Approximately 100-grams of the lathering composition of Table 1 was heated 65° C. and poured into the plastic mold and allowed to completely permeate the mass of discrete black fibers. The lathering composition was then cooled to about 15° C. at approximately 50% RH until solidified and the cleansing article (in the form of a bar) was then removed from the mold.

The overall compositions of the articles are summarized in Table 3,

TABLE 3 Overall composition of article of Example 1 and comparatives 2-3 Example 1 Comparative 1 Comparative 2 Type of included Continuous None Non-continuous polymer network network “network” of (non-woven) of disctrete bonded fibers, polyester fibers, achromatic achromatic (black) (black) L* = 12.4-12.8 L* = 12.4-12.8 Weight of lathering 100 NA composition per gm polymer network Vol % non-woven ~100 NA 80 network (SF3)

Example 1 was judged to be darkest in color and the most opaque. To achieve the same depth of color (if at all) in the comparative 2 or 3 articles a higher level of colorant is required in the lathering composition.

The changes in appearance under conditions that simulate the potential formation of mush that may occur under normal use of the article was estimated using the Soak Test described in the EVALUATION METHODOLOGY section. Briefly, each article was place in an individual rectangular tray that contained a 0.6-0.7 mm layer of deionized water at 25° C. The trays were covered to reduce evaporation. The articles were allowed to sit in the trays for varying periods: 1 hr, 3 hrs, 6 hrs, and 12 hrs and then removed and the surfaces that had been in contact with the water were judged visually. Of the three articles, the water-exposed surface of example 1 was darkest in appearance (essentially remained black) at each soak time and also was very close in appearance to the surface of the article that had not been in contact with water. The water-exposed surface of comparatives 1 and 2 was opaque at short soak times but became white after soak time exceeding 3 hrs. It was found that the water exposed surfaces of comparatives 1 and 2 remained white even after being allowed to dry (wet-side up) for 6 hours

In a third set of simulated discoloration experiments, freshly prepared articles were placed in dry rectangular trays and left exposed to the air (at room temperature for 7 days. Example 1 was judged to change the least in appearance (essentially remained black) relative to comparatives 1 or 2 (surface turned dull gray).

Thus, the inclusion of the substantially black continuous non-woven network provides a darker colored cleansing article utilizing less dye in the lathering composition and provides more resistance to discoloration when exposed to conditions that simulate exposure to water or air.

Example 2-4

The lathering compositions used to make examples 2-4 are shown in Table 4.

TABLE 4 Lathering Composition of Example 2-4 Example 2 COMPONENT (as 100% active) Wt % Example 3 Example 4 Stearic acid/palmitic acid blend 14 Stearic Acid 11.36 11.36 Sodium Tallowate 6.34 6.34 Coconut fatty acid 9 Sodium Cocoate 11.35 11.35 12 hydroxy stearic acid 8.0 8.0 3.5 Lauric acid 3.06 Sodium lauryl sulfate 6.0 6.0 7.20 Sodium Laureth Sulfate 2EO (70%) 4.57 4.57 Sodium C14-16 Olefin Sulfonate 3.89 3.89 Cocoamidopropyl Betaine 6.00 6.00 Disodium Cocoamphodipropionate 5.78 578 Sodium hydroxide 3.94 3.94 2.34 Sorbitol 14.5 Polyethylene Glycol (CARBOWAX 5.0 200) Propylene glycol 2.47 2.47 10.2 Isopropyl alcohol 1.23 Glycerin 4.0 4.0 Hydrogenated Cotton Seed Oil 3.95 3.95 Petrolatum 1.00 1.00 Sunflower Seed Oil 6.00 6.00 Sodium Isethionate 11.98 11.98 HERC Jetine Black (from LCW 1.5 2.5+% 1.5 South Plainfield NJ) Minors (e.g., perfume, preservatives, 1.1 1.1 1.2 etc) Water to 100 to 100 to 100

The lathering composition used in examples 2-3 is an opaque solid, while the lathering composition used in example 4 is transparent. The lathering compositions of examples 2-4 contained the same colorant, namely HERC Jetine Black. Examples 2 and 4 contained the same level of this colorant but a higher level was used in the example 3 composition.

Examples 24 employed as the FPN the same black continuous non-woven pad as was used in example 1 (see Table 2).

To prepare example 2-4, approximately 100-grams of the respective lathering compositions of Table 4 were heated 65° C. (75° C. for example 2 and 3) and poured onto the non-woven pad (3 gm-dimensions: 9 cm×6 cm×2 cm) contained in a plastic mold. The lathering composition was allowed to absorb and completely permeate the network. The resulting intimately blended lathering composition and FPN were then cooled to about 15° C. at approximately 50% RH until solidified and the solidified article (bar shaped) was then removed from the mold. Both articles had the same overall composition as shown for example 1 in Table 3.

The CIE L values of reflected light measured for the three articles were:

Example 2: L* = 60.8 Example 3: L* = 481 Example 4: L* = 24.5

Examples 2-4 illustrate that although opaque and transparent lathering compositions are suitable for forming darkly colored articles of the invention in combination with the polymer network of the invention, the transparent composition has a distinct advantage in requiring less dye and providing articles having a darker color. In fact, with transparent lathering compositions, colorant is often not required if the FPN is sufficiently dark and is composed of a sufficiently high density of fibers similar to the SF-3 batt.

Example 5 and Comparative 4

The lathering composition that may be used in example 5 and comparative 4 is shown in Table 5. This lathering composition is an elastic semi-solid that is transparent, and has a CIE Lightness value of L*=27.5.

TABLE 5 Lathering Composition of Example 5 and Comparative 4 COMPONENT (as 100% active) Wt % Ammonium Lauryl Sulfate 10.13 Ammonium Laureth Sulfate 2EO 7.91 (70%) Cocamide MEA 1.73 PEG-5 Cocamide MEA 0.86 Cocamidopropyl Betaine 10.0 Polyquaternium-10 0.5 Jaguar C13S 0.54 Gelatin Bloom 275 12.00 HERC Jetine Black (from LCW 1.0 South Plainfield NJ) Minors (e.g., color preservatives, 1.8 etc) Glycerin USP 11.0 Polyethylene Glycol 6000 1.0 Water to 100

To prepare Example 5, approximately 100-grams of the lathering composition of Table 5 may be heated 65° C. and poured onto the non-woven pad (3 gm-dimensions: 9 cm×6 cm×2 cm) contained in a plastic mold. The lathering composition would then be allowed to absorb and completely permeate the network. The resulting intimately blended lathering composition and FPN would then be cooled to about 15° C. until the composition set and the elastic semi-solid article (bar shaped) removed from the mold.

Comparative 4 may be prepared in a similar fashion except that the mold would not contain the non-woven polymer network and thus the comparative article is an elastic bar.

Example 5 is expected to be judged darker in color, more opaque and to have a more striking appearance than the comparative 4 article.

Example 5 and comparative 4 may be evaluated for changes in appearance under conditions that simulate the potential formation of mush. The same procedure described above under example 1 would be employed. Example 5 should be less affected by soaking, i.e., its exposed surface should be darker and remain closer in appearance to the surface of the article that had not been in contact with water.

Examples 6-10

These Examples Illustrate Different Fibrous Network.

The lathering composition of Example 1 (Table 1) may be used to prepare cleansing articles that employ the fabricated polymer networks identified in Table 6. These networks are composed of non-woven bonded fibers that differ in porosity and resiliency as defined by the methods described in the EVALUATION METHODOLOGY section. All the networks are achromatic (black) and have an L* value, less than 20. The individual cleansing articles may be prepared by pouring the molten lathering composition into a mold that contains the continuous non-woven network and then solidifying the composition at about 15° C. as discussed in Example 1. The resulting cleansing articles, which should all have a shape similar to a conventional soap bar, are characterized in Table 6.

TABLE 5 Non-woven fabrics used in cleansing articles of Examples 6-10 Non-Woven (FPN) Resiliency % Material of Designation Supplier Porosity Energy Loss Construction LP Den Legget & Platt 0.9835 39.8 PET Salisbury, NC CAR 3 Carlee Corp. 0.9970 41.85 PET Northvale, NJ Kimberly Clark K-C Corp. 0.9943 42.12 PET Neenah, WI SF3 Structured Fibers 0.9951 15.79 PET Saltillo, MS CAR 2 Carlee Corp. 0.9970 39.82 PET Northvale, NJ

The cleansing articles so prepared are described in Table 6. Incorporation of all of the non-woven materials should result in darkly colored cleansing articles that resist discoloration in storage or use.

All the fibrous bars are expected to have good integrity and provide lather during use. However, the amount of lather is expected to depend both on the porosity and the resiliency of the fibrous layer. More resilient structures are expected to maintain adequate dimensional stability over time and over larger number of uses compared to samples that have comparatively poorer resiliency. Specifically, the Percent Energy Loss should be an important parameter as it describes the resilience of the substrate to an applied load. Lower energy loss corresponded to a more resilient fibrous substrate with better in-use properties.

Although all the above example are expected to be robust and provide lather, example 10 which displays the lowest % energy loss values and hence is the most resilient of the fibrous layers tested, should provide the highest lather.

TABLE 6 Description of cleansing articles of Examples 7-10 Exam- Example ple 6 Example 7 Example 8 Example 9 10 Non-woven LPDEN CAR3 KC SF3 CAR2 fibrous layer Weight ratio 100 to 1 100 to 1 100 to 1 100 to 1 100 to 1 of hydrous composition to Non-woven network

Example 11

A cleansing article may be prepared using the lathering composition of example 1 and an FPN consisting of an achromatic open-cell, reticulated polyurethane foam having a CIE Lightness value of less than 15.2. The foam, has a porosity of approximately 3 pores per inch and a density of 1.2 lb/ft³. The procedure would be as follows:

100 gm of the lathering composition is melted and poured into the PVC plastic mold containing a stack of several sheets of the achromatic polyurethane foam (7. cm×20 cm). The mold is cooled to room temperature, stored overnight and the cleansing article removed. The process should produce a darkly colored cleansing article.

Articles that incorporate this type FPN are expected to be found not to provide as much lather as an article employing a continuous network of bonded fibers such as is used in Ex 1 and 6-10.

Examples 12 and 13

The lathering compositions shown in Table 7 may be used to prepare examples 12 and 13. This lathering composition is an elastic semi-solid that is transparent and has a CIE Lightness value of L*=27.5

TABLE 7 Lathering Composition of Example 12-13 Example 12 Example 13 COMPONENT (as 100% active) Wt % Ammonium Lauryl Sulfate 10.13 10.13 Ammonium Laureth Sulfate 2EO 7.91 7.91 (70%) Cocamide MEA 1.73 1.73 PEG-5 Cocamide MEA 0.86 Cocamidopropyl Betaine 10.0 10.0 Polyquaternium-10 0.5 0.1 Jaguar C13S 0.54 Gelatin Bloom 275 12.00 10.0 HERC Jetine Black (from LCW 1 1 South Plainfield NJ) Minors (e.g., color preservatives, 1.8 1.8 etc) Glycerin USP 11.0 1.0 Polyethylene Glycol 6000 1.0 0.28 Water to 100 to 100

The following procedure may be used to prepare Example 12 and 13: Approximately 100-grams of the respective lathering compositions of Table 7 are heated 65° C. and are poured onto the black non-woven pads used in Example 1 (1 gm dimensions: 9 cm×9 cm×2 cm) contained in a plastic mold. The lathering composition is allowed to absorb and completely permeate the network. The resulting intimately blended lathering composition and FPN is then cooled to about 15° C. until the compositions set and the elastic semi-solid articles (bar shaped) are then removed from the mold.

Both the articles of example 12 and 13 should be darkly colored. However, the example 12 article is expected to be more resistant to discoloration during storage than example 13. It is generally found that transparent lathering compositions that include a level of water soluble and non-volatile organic polyols of at least about 10% by weight have better color resistance in open air storage.

Example 14 and Comparative 5

The lathering compositions shown in Table 8A include a hydrophobic organic benefit agent which is a combination of a Type 2 and Type 3 perfume. The amount of sodium hydroxide employed in the Example 14 composition is sufficient to neutralize about half of the fatty acid present so in this case the total surfactant concentration is approximately 21.3%

The lathering composition of example 14 is transparent and contains almost 60% of water and water soluble organic solvent while the composition of comparative 6 corresponds to a conventional opaque soap bar and contains the typical level of water ˜13%.

The finished cleansing articles anticipated are characterized in Table 8B.

The example 14 and comparative 5 articles may be prepared by a melt-cast process as described under Example 1.

Comparative 5 may be prepared by a conventional extrusion and stamping process. The perfume containing hydrophobic Type 2 and Type 3 perfume components would be added immediately before extrusion via a ribbon mixer to minimize perfume loss.

TABLE 8 Lathering Composition of Example 14 and Comparatives 5 Example 14 COMPONENT (as 100% active) Wt % Comparative 5 A. LATHERING COMPOSITION Stearic acid/palmitic acid blend 14 Coconut fatty acid 9 4 12 hydroxy stearic acid 3.5 Lauric acid 3.06 Sodium lauryl sulfate 7.20 Sodium soap (85/15 tallow/cocco) 80.0 Sodium hydroxide 2.34 WATER SOLUBLE ORGANIC SOLVENTS Sorbitol 14.5 Polyethylene Glycol (CARBOWAX 200) 5.0 Propylene glycol 10.2 Isopropyl alcohol 1.23 Glycerin 0.2 Perfume (includes Type 2 and Type 3 1.8 1.8 perfume constituents) Minors (e.g., preservatives, etc) 1.94 0.5 HERC Jetine Black (from LCW South 0.15 0.15 Plainfield NJ) Water 26.2 13.5 (Water + water soluble organic solvents) 57.1 13.5 B. FINISHED CLEANSING ARTICLE FPN (SF-3) same as used in Example 1 2.9 gm FPN per gm lathering composition

The perfume retention on forearms washed in a controlled manner with the Example 14 and Comparative 5 (ordinary soap bar) cleansing articles may be measured by the SPME Analysis of Fragrance Retention method described in the METHODOLOGY SECTION.

The amount of perfume that is retained on the forearm 30 minutes after controlled washing with the exemplary article, example 14 is expected to be over 2 times that retained on forearms washed with the ordinary soap bar (comparative 5). Furthermore, perfume should be still detectable on forearms washed with the exemplary fibrous bar even after 1 hour while essentially no fragrance should be detectable by SPME in the case of the C2 washed forearms.

While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of the invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention. 

1. A darkly colored fibrous bar comprising: i) a continuous fabricated polymer network having a porosity greater than about 0.95 selected from the group consisting of a 3 dimensional bat of a pleated woven or non-woven textile and a reticulated polyurethane or modified polyurethane; ii) a solid or semi-solid lathering composition at least partially encompassing the continuous fabricated polymer network; wherein the continuous fabricated polymer network has a substantially black color defined by having a CIE Lightness Value, L*, of less than 50; wherein the solid or semisolid lathering composition is either transparent or has a substantially black color defined by a CIE Lightness Value, L*, of less than about 60; wherein the fabricated polymer network is at least partially distributed in the solid or semi-solid lathering composition occupying at least about 75% of the volume of said lathering composition; and wherein the weight ratio of the lathering composition to the fabricated polymer network is in the range from about 30 to 1 to about 2000 to
 1. 2. The cleansing article according to claim 1 wherein the fabricated polymer network is a continuous network of bonded fibers.
 3. The cleansing article according to claim 1 wherein the fabricated polymer network is a web comprised of fibers selected from polyethylene terephthalate, polyethylene, polypropylene, polyamide, cellulose, modified or regenerated cellulose, and blends thereof.
 4. The cleansing article according to claim 1 wherein the fabricated polymer network is distributed throughout at least about 55% of the volume of the lathering composition.
 5. The cleansing article according to claim 1 wherein the color of the solid or semi-solid lathering composition has either a blue or green hue.
 6. The cleansing article according to claim 1 wherein the fabricated polymer network and the solid or semi-solid lathering composition are substantially color-matched.
 7. The cleansing article according to claim 1 wherein the solid or semi-solid composition comprises at least 25% by weight of an anionic foaming surfactant selected from the group consisting of C₁₀ to C₁₈ alkyl carboxylates, C₁₀ to C₁₈ alkyl sulfates, C₁₀ to C₁₈ alkyl ethoxy sulfates, C₁₀ to C₁₈ acyl isethionates, and mixtures thereof.
 8. The cleansing article of claim 6 wherein the solid or semi-solid lathering composition further comprises: a) an organic benefit agent having an octanol/water partition coefficient of at least about 500; b) water; c) optionally, a water soluble organic solvent.
 9. The cleansing article of claim 7 wherein the amount of water plus optional water soluble organic solvent is at least about 40% by weight of the lathering composition.
 10. The cleansing article according to claim 1 wherein the fabricated polymer network is at least partially distributed in the solid or semi-solid lathering composition occupying at least about 90% of the volume of said lathering composition. 